Textron Greenlee 1990 User manual

OPERATION MANUAL
999 9994.3 © 2003 Greenlee Textron IM 1093 REV 8 5/03
Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.
1990
Hydraulic Crimping Tool
Serial CodeYM

Greenlee / A Textron Company 24455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
1990 Hydraulic CrimpingTool
Table of Contents
Description .....................................................................2
Safety.............................................................................2
Purpose of this Manual ..................................................2
Important Safety Instructions......................................3-4
Identification................................................................... 5
Specifications.................................................................5
Operation ....................................................................6-7
cUL and UL Classified Crimps.......................................8
Periodic Pressure Relief Valve Check...........................9
Maintenance ..................................................................9
Troubleshooting ...........................................................10
Air Purging and Oil Filling Procedure ..........................11
Exploded View .............................................................12
Parts List ......................................................................13
Description
The 1990 Hydraulic Crimping Tool is a hand-held, self-
contained dieless crimping tool intended to crimp
aluminum and copper connectors onto electrical cable.
The hinged crimping head, which allows easy loading
and unloading of splice connections, swivels 180°for
maximum flexibility. The two-speed hydraulic system
automatically switches from rapid advance (for quick
snug-up) to normal advance (to accomplish the crimp).
An internal pressure regulating system automatically
sets the correct pressure for the connector.
This tool is cUL and UL classified for use as directed on
the cUL/UL Table provided in this manual and on the
carrying case.
The 1990 Crimping Tool is protected by US Patent No.
4,796,461.
Safety
Safety is essential in the use and maintenance of
Greenlee tools and equipment. This manual and any
markings on the tool provide information for avoiding
hazards and unsafe practices related to the use of this
tool. Observe all of the safety information provided.
Purpose of this Manual
This instruction manual is intended to familiarize all
personnel with the safe operation of the Greenlee 1990
Hydraulic Crimping Tool.
Keep this manual available to all personnel.
Replacement manuals are available upon request at no
charge.
KEEPTHIS MANUAL
All specifications are nominal and may change as design improve-
ments occur. Greenlee Textron shall not be liable for damages
resulting from misapplication or misuse of its products.
Blackburn is a registered trademark of Thomas & Betts Corporation.
Dow Corning is a registered trademark of Dow Corning Corporation.
RTV Sealant 732 is a trademark of Dow Corning Corporation.
UL is a registered trademark of Underwriter’s Laboratories,
Incorporated.
UNIVIS is a registered trademark of Exxon Corporation.

Greenlee / A Textron Company 34455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
1990 Hydraulic CrimpingTool
IMPORTANT SAFETY INFORMATION
Inspect tool before use. Replace any worn or
damaged parts. A damaged or improperly
assembled tool can break and strike nearby
personnel.
Failure to observe this warning can result in
severe injury or death.
An incomplete crimp can cause a fire.
• Use proper connector and cable combinations.
Improper combinations can result in an incom-
plete crimp.
• The relief valve will sound to indicate a com-
pleted crimp. If you do not hear the sound of the
relief valve, the crimp is not complete.
Failure to observe these warnings can result in
severe injury or death.
Electric shock hazard:
This tool is not insulated. When
using this unit near energized
electrical lines, use proper personal
protective equipment.
Failure to observe this warning can
result in severe injury or death.
Wear eye protection when operating
or servicing this tool.
Failure to wear eye protection can
result in serious eye injury from
flying debris or hydraulic oil.
Skin injection hazard:
Oil under pressure easily punctures
skin causing serious injury, gan-
grene or death. If you are injured by
escaping oil, seek medical attention
immediately.
• Do not use hands to check for
leaks.
• Depressurize the hydraulic system
before servicing.
This symbol is used to call your attention to hazards
or unsafe practices which could result in an injury
or property damage. The signal word, defined below,
indicates the severity of the hazard. The message
after the signal word provides information for
preventing or avoiding the hazard.
Hazards or unsafe practices which, if not avoided,
MAY result in injury or property damage.
Hazards which, if not avoided, COULD result in
severe injury or death.
Immediate hazards which, if not avoided, WILL result
in severe injury or death.
SAFETY
ALERT
SYMBOL
Read and understand all of the
instructions and safety information
in this manual before operating or
servicing this tool.

Greenlee / A Textron Company 44455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
1990 Hydraulic CrimpingTool
IMPORTANT SAFETY INFORMATION
Note: Keep all decals clean and legible. Replace decals
when necessary.
Keep hands away from the crimping
tool head when crimping.
•This tool is intended for two-handed operation.
Maintain a firm grip on both handles during
operation. Using this tool in any other manner can
result in injury or property damage.
•Do not perform any service or maintenance other
than as described in this manual. Injury or damage
to the tool may result.
Failure to observe these precautions can result in
injury and property damage.

Greenlee / A Textron Company 54455 Boeing Dr. •Rockford, IL 61109-2988 USA •815-397-7070
1990 Hydraulic CrimpingTool
Identification
Specifications
Crimping Tool
Length..................................................................................... 673 mm (26.5")
Width...................................................................................... 26.3 mm (2.87")
Mass/Weight ............................................................................ 7.5 kg (16.5 lb)
Hydraulic Oil ............................................................................. 198 cc (12 in3)
Crimping Capacities
Crimping Range
Copper Connectors ............................25–500 mm2(4 AWG–1000 kcmil)
Aluminum Connectors ........................16–500 mm2(6 AWG–1000 kcmil)
Maximum Crimper Diameter.......................................... 461 mm (1.815")
Crimping Force (maximum) .................................................. 133 kN (15 tons)
Crimping Tool Adjusts Automatically to Connector Size
MOVABLE
PIN UNIT
RELEASE
TRIGGER
RAM DIE
DIE HEAD

Greenlee / A Textron Company 64455 Boeing Dr. •Rockford, IL 61109-2988 USA •815-397-7070
1990 Hydraulic CrimpingTool
Operation
Preparation
1. Select a proper size and type of connector to
correspond with the wire or cable.
2. Strip the cable to an appropriate length. Follow the
connector manufacturer’s instructions.
Note: Apply an oxide inhibitor, if required. See the
connector manufacturer’s instructions.
Crimping
1. Insert the cable fully into the connector.
2. Position the connector in the crimping head.
Note: Position lug connectors so the tang is
perpendicular to the direction of ram travel, as
shown.
Electric shock hazard:
This tool is not insulated. When
using this unit near energized
electrical lines, use proper personal
protective equipment.
Failure to observe this warning can
result in severe injury or death.
Wear eye protection when operating
this tool.
Failure to wear eye protection can
result in serious eye injury from
flying debris or hydraulic oil.
Inspect tool before use. Replace any worn or
damaged parts. A damaged or improperly
assembled tool can break and strike nearby
personnel.
Failure to observe this warning can result in
severe injury or death.
An incomplete crimp can cause a fire.
•Use proper connector and cable combinations.
Improper combinations can result in an incom-
plete crimp.
•The relief valve will sound to indicate a com-
pleted crimp. If you do not hear the sound of the
relief valve, the crimp is not complete.
Failure to observe these warnings can result in
severe injury or death.
For a cUL or UL classified crimp, see the connec-
tor table in this instruction manual.
Keep hands away from the crimping
tool head when crimping.
DIRECTION OF RAM TRAVEL
TANG

Greenlee / A Textron Company 74455 Boeing Dr. •Rockford, IL 61109-2988 USA •815-397-7070
1990 Hydraulic CrimpingTool
Operation (cont’d)
3. If open, close the die head and push in the movable
pin unit. Make sure the movable pin is fully
engaged.
4. Align the tool with the alignment mark (for lugs) or
center stop (for sleeves) as shown.
5. Pump the handle to advance ram. Continue to
pump until the pressure relief valve activates.
Note: Pressure relief is indicated by an audible
“pop”and a sudden drop in handle force.
6. To release the hydraulic pressure, pull the release
trigger back while pressing down on the handle.
Note: To prevent the ram from retracting
completely, release the trigger. This speeds the
crimping process when a single connector requires
several crimps.
7. For a cUL or UL classified crimp, complete the
number of crimps specified in the cUL/UL Table.
Note: For brands not listed, consult the connector
manufacturer’s instructions to determine the number
of crimps and the acceptability of installation with a
dieless tool.
8. To remove the tool from a splice, pull the movable
pin on the die head and open the crimping head.
OUTERMOST
BLADE OF DIE HEAD
LUG
ALIGNMENT
MARK
LONGER LUG
TANG
OUTERMOST
BLADE OF RAM DIE
LUG
ALIGNMENT
MARK
SHORTER LUG
TANG
OUTERMOST
BLADE OF DIE HEAD
CENTER
STOP
SLEEVE

Greenlee / A Textron Company 84455 Boeing Dr. •Rockford, IL 61109-2988 USA •815-397-7070
1990 Hydraulic CrimpingTool
cUL and UL Classified Crimps
The 1990 Hydraulic Crimping Tool is cUL and UL classified* for use with the following connectors:
cUL/ULTable
ROTCENNOC
EPYT NOSREDNANRUBKCALB

YDNRUBICFOCSLI**B&T ENYDELET
NOINU-NNEP
①ERIW
EZIS
FO.ON
***SPMIRC
detaRlauD munimulA seveelS SCAVPSAA-SYSA48506–70506KIP –GWA6 GWA0/4 1
detaRlauD munimulA sguL LCAVLTA A-AY NTA-AY NCA/LCA NCA2/LCA2 48106–60106 48206–03206 AULB
–limck052 limck0001 roreppoC munimulA
2
reppoC seveelS SSHV/SHVUC/PSCL-SY/SYLTC/TC 82545–60545 82845–60845 UCB UCBB –GWA4 limck0001 reppoC 1
sguLreppoCLCHV 2-LTC NLC/L-LTC LTC
L2-AY/L-AY/AY N2-AY/NL2-AY CT2-L-AY/CT-L-AY
BRC/ARC L-BRC/L-ARC L2-ARC L2-BRC 82145–60145 82245–60245 82945–60945 28845–45845
ULB ULBB
munimulA niP rotcennoC PEC— PYA
MCA –GWA6 limck0001 LA
—PT–GWA6 limck057 munimulA 1
munimulA tesffO rotcennoC OPEC— OPYA
OCA –GWA6 limck0001 LA
—OPT –GWA6 limck057 munimulA 1
reppoC liatgiP retpadA —— —
MPC
——
–GWA6 limcK005 munimulA
1
UC9LAMPC
–GWA6 limck005 roreppoC munimulA
①
*
*****
.srotcudnocmunimuladnareppocdednartshtiwesuroF
DETONSATPECXE
.srotcudnocmunimuladnareppocdednartstcapmocrodesserpmoc,cirtnecnocdradnatshtiwdesunehW .0991ehtfoyticapacdetarehtnihtiwezisrotcennocahtiwdesunehwylnO .rotcennocehthtiwdedivorprebmunfodaetsninmulocsihtnidetsilspmircforebmunehtesu,0991ehthtiwgnipmircnehW
95R7

Greenlee / A Textron Company 94455 Boeing Dr. •Rockford, IL 61109-2988 USA •815-397-7070
1990 Hydraulic CrimpingTool
Periodic Pressure Relief Valve Check
Test the crimping tool periodically to ensure that the
pressure relief valve activates at the proper pressure.
Order crimping tool test kit, Greenlee part number
503 2891.3.
Testing the Crimping Tool
1. Center a new pressure test slug in the crimping
head.
2. Pump the handles to advance ram. Continue to
pump until the pressure relief valve activates.
3. To release the hydraulic pressure, pull the release
trigger back while pressing down on the handle.
4. Repeat Steps 1–3 on two more test slugs.
5. Test the three slugs as follows against the GO/NO
GO gauge as shown.
•If the GO slot will fit over the slug and the NO GO
slot will not, the pressure is within the specified
range.
•If the GO slot will not slide over the slug, the
crimping pressure is too low. Send the crimping
tool to an authorized service center.
•If the NO GO slot will slide over the slug, the
crimping pressure is too high. Send the crimping
tool to an authorized service center.
The pressure test slugs are manufactured to a
precise diameter and hardness. Do not re-use the
test slugs. Discard each slug after use.
Maintenance
•After using the tool, remove any dirt, grit, or oxide
inhibitor from the tool.
•Occasionally lubricate moving parts.
•Store the tool in its case with the ram fully retracted.
•Perform the Periodic Pressure Relief Valve Check
every 500 crimps or every 90 days, whichever comes
first.
“GO”GAUGE “NO GO”GAUGE
CHECK POINT (center depression
of the three depression side)
6. Discard the slugs.

Greenlee / A Textron Company 10 4455 Boeing Dr. •Rockford, IL 61109-2988 USA •815-397-7070
1990 Hydraulic CrimpingTool
Troubleshooting
PROBLEM PROBABLE CAUSE POSSIBLE REMEDY
Ram does not advance. Air in the hydraulic system. See Air Purging and Oil Filling Procedure.
Check valve or release mechanism. Return tool to an authorized service center.
Ram advances slowly. Air in the hydraulic system. See Air Purging and Oil Filling Procedure.
Check valve or release mechanism. Return tool to an authorized service center.
Ram advances erratically. Air in the hydraulic system. See Air Purging and Oil Filling Procedure.
Ram retracts partially with Air in the hydraulic system. See Air Purging and Oil Filling Procedure.
each stroke. Check valve. Return tool to an authorized service center.
Ram does not fully advance. Hydraulic fluid level is low. See Air Purging and Oil Filling Procedure.
Ram does not fully retract. Air in the hydraulic system. See Air Purging and Oil Filling Procedure.
Reservoir is overfilled. See Air Purging and Oil Filling Procedure.
Internal binding. Return tool to an authorized service center.
Ram does not retract. Dies damaged. Return tool to an authorized service center.
Release mechanism. Return tool to an authorized service center.
Pressure builds slowly; Discharge check ball. Flush valve seat using rapid pump strokes.
handle springs back. If unit still does not work, return tool to an
authorized service center.
Pressure builds slowly; Relief valve or release mechanism. Return tool to an authorized service center.
no response.
No high pressure. Check valve. Flush valve seat using rapid pump strokes.
If unit still does not work, return tool to an
authorized service center.
Air in hydraulic system. Improper fill procedure. See Air Purging and Oil Filling Procedure.
Loose or missing reservoir plug. Replace plug.
Reservoir damaged. Replace reservoir.
Reservoir missing O-ring. Replace O-ring.
Damaged O-ring on low pressure Return tool to an authorized service center.
injector.

Greenlee / A Textron Company 11 4455 Boeing Dr. •Rockford, IL 61109-2988 USA •815-397-7070
1990 Hydraulic CrimpingTool
Air Purging and Oil Filling Procedure
Fill the reservoir with Exxon UNIVIS®J26 all tempera-
ture hydraulic oil only.
2. Retract the ram by pulling the release trigger back
while pressing down on the handle.
3. Pump the handle one partial stroke.
4. Peel out the rubber plug (26) and remove the set
screw (27) from the reservoir handle (1).
Do not fill the hydraulic reservoir with any other
type of fluid (such as brake fluid, glycerine, castor
oil, etc.).
Filling the reservoir with anything other than
hydraulic fluid will damage the tool and void the
warranty.
8. Pump the handle several times to advance the ram.
While holding a CLEAN shop cloth over the reser-
voir, retract the ram fully. Repeat several times to
purge all of the air from the system.
9. With the pump handle vertical and the ram fully
retracted, fill the reservoir until it overflows.
10. Replace the plug (25) and wipe off excess oil.
11. Pump the handle one stroke and install the reser-
voir handle (1). Replace the set screw (27).
12. Cover the set screw with a silicone rubber sealant,
such as Dow Corning®RTV Sealant 732™Multi-
Purpose Sealant.
1. Clamp the tool into a vise with jaw protectors so the
handles are upward, as shown.
5. Unscrew the reservoir handle from the crimping
tool. Remove the plug (25) from the reservoir.
6. Retract the ram fully.
7. Add oil until the reservoir overflows.
VISE WITH JAW
PROTECTORS
RUBBER
PLUG (26)
REMOVE
SET SCREW
(27)
RESERVOIR
PLUG
(25)

Greenlee / A Textron Company 12 4455 Boeing Dr. •Rockford, IL 61109-2988 USA •815-397-7070
1990 Hydraulic CrimpingTool
ExplodedView
7
17
29
5
4
2
3
23
24
25
22
16 21
27
26
1
18
19
20
28
15
16
14
13
10
11
12
8
15
6
9
24
Torque cap screws (13) to 20.3 Newton-meters (15 foot-pounds).
1
1

Greenlee / A Textron Company 13 4455 Boeing Dr. •Rockford, IL 61109-2988 USA •815-397-7070
1990 Hydraulic CrimpingTool
Parts List
KEY UPC NO. PART NO. DESCRIPTION QTY.
78-3310-
1 35680 503 5680.1 Handle, Reservoir ............................................................................... 1
2 35689 503 5689.5 Grip, Reservoir Handle ....................................................................... 1
35671 503 5671.2 Handle Unit, Pump (consists of 3–11)................................................ 1
3 35688 503 5688.7 Grip, Rubber ....................................................................................... 1
4 35672 503 5672.0 Handle, Pump ..................................................................................... 1
5 51048 905 1048.8 Pin, Roll, .125 x .625 .......................................................................... 1
6 53475 905 3475.1 Pin, Roll, .156 x 1.375 ........................................................................ 2
7 35698 503 5698.4 Rod, Pressure Release ...................................................................... 1
8 50485 905 0485.5 Pin, Roll, .125 x .375 .......................................................................... 1
9 03427 500 3427.8 Trigger, Release ................................................................................. 1
10 03334 500 3334.4 Spring, Torsion, .187 x .280 x .312 .................................................... 1
11 35697 503 5697.6 Bar, Pressure Release ....................................................................... 1
12 32493 503 2493.4 Lever, Pivot......................................................................................... 1
13 51265 905 1265.0 Screw, Cap, 1/4 - 20 x .750 Socket Head.......................................... 2
14 35676 503 5676.3 Pin, Fulcrum........................................................................................ 1
15 52336 905 2336.9 Ring, Retaining, .312 Truarc .............................................................. 2
16 51379 905 1379.7 Ring, Retaining, .500 Truarc .............................................................. 2
17 32514 503 2514.0 Die, Ram ............................................................................................. 1
18 35677 503 5677.1 Head, Die ............................................................................................ 1
19 53962 905 3962.1 Detent, Ball ......................................................................................... 1
20 52338 905 2338.5 Screw, Set, #10 - 32 x .250 Socket.................................................... 1
21 35678 503 5678.0 Pin Unit, Movable ............................................................................... 1
22 35673 503 5673.9 Pin, Pivot, .468 x 2.05 ........................................................................ 1
23 53814 905 3814.5 O-ring, 1.47 x 1.71 x .118................................................................... 1
24 35686 503 5686.0 Reservoir ............................................................................................ 1
25 32488 503 2488.8 Plug, Rubber Reservoir ...................................................................... 1
26 Dow Corning Silastic 732 RTV (clear or green)................(as needed)
27 51241 905 1241.3 Screw, Set, #10 - 32 x .187 Socket Flat Point ................................... 1
28 33730 503 3730.0 Spacer, .549 x .997 x .025 ................................................(as needed)
29 35462 503 5462.0 Decal, Warning ................................................................................... 1
Decals (not shown):
32792 503 2792.5 Decal, Identification ............................................................................ 1
35463 503 5463.9 Decal, Connector Chart ...................................................................... 1
06243 500 6243.3 Decal, Instruction/Operating............................................................... 1
06233 500 6233.6 Decal, Safety ...................................................................................... 1
Not Shown:
32791 503 2791.7 Carrying Case..................................................................................... 1
32891 503 2891.3 Calibration Test Kit (includes 30 test slugs and gauge) .................... 1
35373 503 5373.0 Exxon UNIVIS®J26 Hydraulic Oil......................................(as needed)
32892 503 2892.1 Gauge Pressure Test ......................................................................... 1
32893 503 2893.0 Slug Pressure Test ............................................................................. 7

Printed in USA
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International [phone] Fax: [phone]
4455 Boeing Drive, Rockford, IL 61109-2988 •USA •815-397-7070
An ISO 9001 Company •Greenlee Textron is a subsidiary of Textron Inc.
www.greenlee.com